Lukas traversing system User Manual

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Instruction Manual

30000085 E

Rerailing Equipment

LUKAS traversing system

(Translation of the original instruction manual)

1430000085 EN

Edition 09.2014

Edition 09.2

Content Page

1. Danger classiﬁ cations 4

2. Product safety 5

3. Proper use 8

4. Components and functions 9

4.1 Description 9

4.2 Hydraulic supply to the cylinders 10

5. Connecting the hydraulic equipment 10

5.1 Basic aspects 10

5.2 Coupling the quick-disconnect couplings 11

6. Operation 12

6.1 Setting up the LUKAS traversing system 12

6.2 Start-up 25

6.3 Controlling the LUKAS traversing system with anchor pin 26

6.4 Controlling the DUO traversing cylinder with anchor cylinder 28

7. Dismantling the equipment / deactivation following operation 30

7.1 Hydraulic cylinder 30

7.2 Hoses 30

7.3 Additional components of the traversing system 30

7.4 Hydraulic supply, control and separate load lifting systems 30

8. Maintenance and service 31

9. Repairs 31

9.1 General information 31

9.2 Preventative service 32

9.3 Repairs 33

10. Troubleshooting 36

11. Technical data 38

11.1 Traversing cylinder 38

11.2 Rolling carriage 41

11.3 Rerailing bridges 41

11.4 Connecting rods 42

11.5 Recommended hydraulic ﬂ uids 43

11.6 Operating and storage temperature ranges 43

12. Declaration of conformity 44

13. Notes 45

1. Danger classiﬁ cations

We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the speciﬁ c danger and the possible consequences.

Pictogram

Damage /

injury to

Persons

Property

- NOTE

Key word Deﬁ nition Consequences

DANGER! Immediate danger

WARNING!

CAUTION!

ATTENTION!

Potentially dangerous

situation

Less dangerous

situation

Danger of damage

to property/

environment

Handling tips and

other important/

useful information

and advice

Death or severe

injury

Potential death or

serious injury

Minor or slight

injury

Damage to the

equipment,

damage to the

environment,

damage to

surroundings

No injury/damage

to persons/

environment/

device

Wear a helmet with a face guard

Wear protective gloves

Wear safety shoes

Proper recycling

Protect the environment

Read and follow the operating instructions

2. Product safety

LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The safety of the operator is the most important consideration in product design. Furthermore, the operating instructions are intended to help in using LUKAS products safely. The generally applicable legal and other binding regulations pertaining to the prevention of accidents and protection of the environment apply and are to be complied with in addition to the operating instructions. The equipment must only be operated by persons with appropriate training in the safety aspects of such equipment – otherwise, there is a danger of injury. We would like to point out to all users that they should read carefully the operating instructions and the instructions contained therein before they use the equipment, and that they should carefully follow such. We further recommend you have a qualiﬁ ed trainer show you how to use the product.

CAUTION!

The operating instructions for the hoses, the accessories and the connected devices must also be heeded!

Even if you have already received instruction on how to use the equipment, you should still read through the following safety instructions again.

WARNING / CAUTION!

Ensure that the accessories and connected equipment are suitable for the maximum operating pressure!

Please ensure that no body parts or clothing are caught between the visibly moving parts (e.g. piston guard plate and cylinder).

Wear protective clothing, a safety helmet with visor, protective footwear and gloves

Immediately report any changes that occur (including changes in operating behaviour) to the appropriate persons/departments! If necessary, the equipment is to be shut down immediately and secured!

Working under suspended loads is not permitted where such loads are being lifted only using hydraulic devices. If working under suspended loads is unavoidable, suitable mechanical props are also required.

Inspect the device before and after use for visible defects or damage.

Check all lines, hoses and screwed connections for leaks and externally visible damage, and repair immediately! Escaping hydraulic ﬂ uid can cause injuries and ﬁ res.

In the event of malfunctions, immediately deactivate the equipment and secure it. Repair the fault immediately.

Do not carry out any changes (additions or conversions) to the equipment without obtaining the approval of LUKAS beforehand.

Observe all safety and danger information on the device and in the operating instructions.

Any mode of operation which compromises the safety and/ or stability of the device is forbidden!

Safety devices must never be disabled!

Make sure before switching on/starting up the device and during its operation, that this will put no one in danger.

When working close to live components and cables, suitable measures must be taken to avoid current transfers or high-voltage transfers to the equipment.

All safety and danger information on the device must always be complete and in a legible condition.

Observe all intervals for recurring tests and/or inspections that are prescribed or stated in the operating instructions.

The maximum permitted operating pressure noted on the equipment must not be exceeded.

Only genuine LUKAS accessories and spare parts are to be used for repairs.

Please ensure that, when working with this equipment or during transportation of such, you don’t get caught up in the looped hoses and trip.

The build-up of static charge and therefore possible sparking must be avoided when handling the device.

The equipment is ﬁ lled with hydraulic ﬂ uid. This hydraulic ﬂ uid can be detrimental to health if it is swallowed or its vapour is inhaled. Direct contact with the skin must be avoided for the same reason. Also, when handling hydraulic ﬂ uid, note that it can negatively affect biological systems.

When working with or storing the equipment, ensure that the function and the safety of the equipment are not impaired by the effects of severe external temperatures or that the equipment is damaged in any way. Please note that the equipment can also heat up over a long period of use.

Make sure there is adequate lighting while working.

Always keep these operating instructions easily accessible at the place of operation.

In addition to the safety instructions in this operating manual, all generally applicable, statutory and otherwise binding national and international regulations for accident prevention must be heeded and disseminated!

Before transporting the equipment, always ensure that the accessories are positioned in such a way that they cannot cause an accident.

Dispose properly of all disassembled parts, oil and left-over ﬂ uid, as well as packaging materials.

WARNING / CAUTION / ATTENTION!

The device is intended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not considered to be as intended. The

manufacturer/supplier is not liable for any damage resulting from use not as intended. The user bears sole responsibility for such use. Proper use includes observance of the operating instructions and compliance with the inspection and maintenance conditions.

Never work in a fatigued or intoxicated state!

3. Proper use

The components of the LUKAS traversing system are especially designed for re-railing technology . They are used for rerailing of rail-bound vehicles. Derailed vehicles can be lifted up and moved at right angles to the track. The accessories necessary for the particular application, such as base plate, multistage sets etc., must be used during each deployment.

When carrying out any work, use the traversing system described here and the connected hoses and equipment to ensure that you yourself, the involved and uninvolved persons in the proximity of the work and objects in closer proximity during the lifting and traversing process are not endangered.

ATTENTION!

Watch out vigilantly for any leaks in order to avoid threats to the environment.

The LUKAS traversing system consists of:

- Item 1 Rerailing bridge

- Item 2 DUO traversing unit

- Item 3 Rolling carriage

- Item 4 Adjustable connecting rods

NOTE:

In order to be able to lift vehicles and move them, either lifted up or placed on the traversing system, you need to use suitable lifting equipment (e.g. LUKAS HP cylinders) and their accessories.

4. Components and functions

4.1 Description

4.1.1 Rerailing bridge

The rerailing bridge is placed at right angles over the tracks and provides the support and moving surface for the LUKAS rolling carriages and the DUO traversing unit. If one bridge is not long enough, a second bridge can be screwed on by means of joining elements. The integrated anchor cylinder locates as a locking pin in the arresting openings in the top of the rerailing bridge. The rerailing bridges are transported using the pull-out handles mounted at the sides.

4.1.2 Rolling carriages

The LUKAS rolling carriages are designed to carry heavy loads. The special rollers on the bottom of the rolling carriage mean that it can be moved in the rolling direction by hand or using traversing cylinders. The rolling carriages are specially adapted to LUKAS rerailing bridges and provide optimum movement for the load. The top slide plate on the rolling carriage is placed on the carriage and can be rotated and moved at right angles to the rolling direction. The movements arising during lifting and traversing are thus given more room. Tipping of the rolling carriage or a cylinder mounted on it is prevented if positioned correctly.

4.1.3 DUO traversing unit

The DUO traversing unit is designed to move the LUKAS rolling carriages on the rerailing bridges. The traversing cylinder is a double-acting hydraulic cylinder whose piston rod end is hooked into the ﬁ xing point provided on the rolling carriage. This makes it possible to move the rolling carriage in the retraction and extension directions of the traversing cylinder. The anchor cylinder serves as the locking pin.

The DUO traversing unit is available in two different variants.

1) One variant has a ﬁ xed pin which locks the traversing cylinder in the ﬁ xing points on the LUKAS rerailing bridge.

2) The other variant instead has an integrated anchor cylinder that can be retracted and extended hydraulically. In addition, this variant has lateral guide plates on the anchor cylinder to provide stabilisation. The advantage of the version with an anchor cylinder is that the cylinder can be reset without the user having to enter the danger area. In the unloaded condition, this cylinder is always extended, so that, in the event of a loss of pressure in the hydraulic system, there is still an anchoring in the rerailing bridge. When pressurised, the anchor cylinder retracts and allows the traversing cylinder to move by extending or retracting.

A prerequisite for the operation of both variants is that the rerailing bridge is aligned horizontally and that the load is lifted in such a way that there is no danger of the load suspended in this way rolling away to the side.

4.1.4 Connecting rods

The connecting rods are used if a load is to be lifted at two or more points and then is to be moved, at the same time, using rolling carriages in one direction. The connecting rods are always used in pairs and connect the rolling carriages together. The connecting rods have a coarse and a ﬁ ne setting facility in order to be able to set them precisely to the distance between the individual lifting points.

4.2 Hydraulic supply to the cylinders

Only the speciﬁ ed LUKAS hydraulic power packs (motor pumps) or suitable LUKAS hand pumps can be used to drive the equipment. If the pump unit is a different make, you must make sure that it complies with LUKAS speciﬁ cations, otherwise potential dangers may occur which are not the responsibility of LUKAS. Ensure in particular that the maximum permissible operating pressure for the connected LUKAS equipment is not exceeded.

NOTE:

Before you use pumps from a different manufacturer, you must contact LUKAS or an authorised dealer.

The connection between the hydraulic power pack (pump unit) or hand pump and the hydraulic cylinders is by hoses.

5. Connecting the hydraulic equipment

5.1 Basic aspects

On the double-acting hydraulically-actuated working equipment, there is, on the pressure supply side (with cylinders: on the cylinder base side) a plug coupling nipple

and on the return side (with cylinders: on the piston rod side) a plug connection sleeve; and these are connected to the control unit by pairs of hose extensions.

A plug connection nipple is provided on the single-acting hydraulically-actuated working equipment; and this is connected to the pump unit or control unit via hose extension.

If you are using single-acting cylinders (particularly of a previous type), LUKAS recommends that you contact LUKAS or an authorised dealer. Using single-acting locking-cylinders a

sticker (accessory order no. 43010073) is available to simplify operation. For unlocking the control leaver must be pulled in direction of the the operator.

The hose extension pairs are supplied in various lengths. The individual hoses can, if required, also be marked with coloured snap rings to make it easier to allocate the hoses.

(For speciﬁ c details, please consult the LUKAS range of accessories or contact your LUKAS dealer.)

WARNING / CAUTION / ATTENTION! Prior to connecting the devices, ensure that all the components

being used are suitable for the maximum operating pressure of the pump unit! In case of doubt you must consult LUKAS

directly!

5.2 Coupling the quick-disconnect couplings

The device is connected to the hydraulic pump without risk of misconnection using monocoupling halves (female and male coupling).

Before coupling, remove dust caps and then pull back and hold the locking sleeve of the female coupling half (position X). Connect the male and female couplings and release the locking sleeve. Then turn the locking sleeve to position Y. The connection has been made and locked. Uncoupling is done in the reverse order. Coupling of the devices is only possible, when the hoses are depressurised. For dust protection, the supplied dust caps must be reﬁ tted.

ATTENTION!

Always connect the return line ﬁ rst and then the supply line!

NOTE:

Coupling of the devices is only possible, when the hoses are depressurised.

For dust protection, the supplied dust caps must be reﬁ tted.

WARNING / CAUTION / ATTENTION! Some quick-disconnect couplings have special functions.Therefore, you must

not unscrew them from the hoses or swap them over!

6. Operation

6.1 Setting up the LUKAS traversing system

6.1.1 General

The LUKAS traversing system consists of several individual components. Appropriate combination of the individual components can be used to set up various different total systems. With some of these overall systems, not all the individual components are required, and on others you will need several of the individual components. In addition to the individual components of the LUKAS traversing system, suitable hydraulic cylinders will be required for lifting the load and at least one suitable hydraulic power pack or a suitable hand pump will be needed to provide the pressure.

6.1.2 Basic work required for setting up the traversing system

CAUTION / ATTENTION!

Prior to setting up the individual components of the LUKAS traversing system, the load to be lifted must be secured against slipping as prescribed in the respective applicable guidelines and regulations. The relevant rerailing concepts of the vehicle manufacturer must be observed.

Before setting up the traversing system, check the individual components for visible damage.

You must always take into account the following when setting up the components of the traversing system:

- Please ensure that the load is applied centrally to the piston rod or rolling carriage plate.

NOTE:

Select the more favourable load grip point in order to guarantee maximum safety!

Position the cylinder/rolling carriage underneath the centre of gravity of the load, such that the load cannot tip over during lifting and endanger the operating staff or the equipment being used. The load should always act centrally on the piston surface or the surface of the rolling carriage plate. Avoid lateral forces acting on the cylinder! Frequently it is not possible to apply the load on the full cylinder surface. LUKAS also

Load

WRONG RIGHT

Load

recommends the use of suitable piston guard plates for this reason, as otherwise there is a risk of damage to the piston rod or the cylinder. A convex piston guard plate distributes the load evenly over the piston area again. If several cylinders/rolling carriages are used simultaneously, the load should be distributed as evenly as possible over all cylinders/rolling carriages.

Load

WRONG

The following must always be observed when installing the cylinders:

Load share 1

Load proportion 1 < Load proportion 2

WRONG RIGHT

- non-slip and even ground, so that the entire base area of the cylinder is in contact with the ground. If there is any doubt as to the load-bearing capacity of the ground, suitable wooden or metal underplates (blocks) must be used to increase the contact area.

- The area of support must be a continuous level surface (not a grating, gravel etc.)

Load share 2

Load share 1

Load proportion 1 = Load proportion 2

Load

RIGHT

Load share 2

WRONG

ATTENTION!

Hydraulic ﬂ uids may produce a lubricating ﬁ lm on the ground!

- Never place cylinders on a yielding underplate

- Never use cylinders without a piston guard plate, in order to avoid damage to the piston

RIGHT

and achieve safe power introduction

- Please ensure that the load is applied centrally to the piston rod.

- Stability and load application is improved if you use load distribution plates. Distribution plates permit an angle of inclination of 5 °.

ATTENTION!

Observe the permissible angle of inclination when lifting the vehicle!

6.1.3 Setting up the rerailing bridges

The bridge is placed across the tracks and carefully supported by wooden planks. Please observe that:

- The rerailing bridge and the supporting wooden beam packers are on a non-deﬂ ecting

ﬁ xed subsurface.

CAUTION / ATTENTION!

When using wooden underplates, care must be taken that particularly hard wood without damage is used, so that the underplate cannot crack. Strapping additional pieces of wood together with metal bands is not sufﬁ cient!

- The maximum load of the bridge is not exceeded. See the following table.

Bridge height Support width Max. load

[mm] [m] [kN]

[in.] [ft.] [lbs.]

85 0 350

3.35 0 787000

140 0 1000

5.51 0 225000

184 0 1200

7.24 0 270000

* *

160

3.28 13500

1.43 50

4.69 11200

* *

1 500

3.28 112000

1.43 400

4.69 90000

* *

1 900

3.28 202000

1.43 650

4.69 146000

* completely packed up

- The maximum load of the bridge connecting elements (optional) is not exceeded:

Bridge height Support width Max. load

[mm] [m] [kN]

[in.] [ft.] [lbs.]

85 1 20

3.35 3.28 4500

140 1 200

5.51 3.28 45000

184 1 300

7.24 3.28 68000

- the bridge is horizontally aligned:

The angle of the bridge may not exceed 3°. If one bridge is not long enough, a second bridge can be screwed on by means of joining elements. This done by placing the ends of the rerailing bridges together and bolting them together using ﬂ at steel plates, bolts, washers and nuts (as shown in the illustration below). You must ensure that the top running surfaces of the rerailing bridges are not offset to each other axially, since otherwise proper movement cannot be guaranteed and/or this can lead to damage to the individual components.

6.1.4 Setting up the rolling carriages

The rolling carriages are mounted on the rerailing bridges in such a way that the rollers of the rolling carriages can move along the rerailing bridges. The guides on the rolling carriages prevent it from slipping off the rerailing bridge to the side.

6.1.5 Setting up hydraulic cylinders on the rolling carriages

The hydraulic cylinders are placed centrally on the top carrier plate of the rolling carriage if they are to be moved along with the lifted load (see illustration below).

CAUTION / ATTENTION!

When traversing a load lifted by a hydraulic cylinder (upright on the rolling carriage), you need to ensure that the load cannot tip over during traversing. Loads are more safely traversed by lifting them externally by hydraulic cylinders, then placed on the rolling carriage and only then traversed.

ATTENTION!

When commissioning you must observe all the instructions and regulations in the separate operating instructions for the cylinders being used!

NOTE:

We recommend using a foot-plate from the LUKAS accessories programme if you wish to traverse a hydraulic cylinder standing on the rolling carriage. The foot-plates provide assistance in providing a solid base for the cylinder and by counteracting the tip movement during traversing. The foot-plate must always be fully packed-up when in use.

6.1.6 Setting up the traversing cylinder with ﬁ xed anchor pin

Insert the traversing cylinder with the ﬁ xed anchor pin in one of the suitable mounts (slotted holes) in the rerailing bridge, and hook it into the middle mount for the rolling carriage with the piston rod head (see illustration below). It may be necessary to move the rolling carriage slightly to allow the cylinder head to be hooked in.

NOTE:

The LUKAS traversing system must be set up in consideration of the traversing device and the traversing distance.

6.1.7 Setting up the traversing cylinder with anchor cylinder (double-acting)

Insert the traversing cylinder with the head of the anchor cylinder in one of the matching mounts in the rerailing bridge. To do this you must slide the slide plate at the back end of the traversing cylinder upwards slightly . Then suspend the traversing cylinder with the piston rod head in the middle mount in the rolling carriage (see illustration below). It may be necessary to move the rolling carriage slightly to allow the cylinder head to be hooked in.

Now pull the slide plate upwards to the stop and apply the guide plates on the right and left on the traversing cylinder.

Move the applied guide plates towards the cylinder head and slide the slide plate back down. The traversing cylinder is now secured against lateral traversing and against lifting.

6.1.8 Setting up and adjusting the connecting rods

The distance between the load lift points must be set precisely using the connecting rods. For this reason you have a coarse and ﬁ ne adjustment facility.

Coarse setting of the connecting rods:

1. Remove the locking pin.

2. The coupling rod can now be pulled out and this allows coarse setting of the distance of

the rolling carriages. The hole in the coupling rod must line up with a hole in the pipe in order to be able to insert the locking pin.

3. Insert the locking pin back into the relevant hole in the pipe.

Fine setting of the connecting rods:

The ﬁ ne setting is carried out at the other end of the pipe. Insert a metal rod (ø8 mm) or a similar tool into the cross-hole of the adjusting bolt and unscrew it (anticlockwise), until the desired distance is reached. The adjusting bolt can be unscrewed maximum 80 mm in order to carry out the ﬁ ne adjustment.

Connecting two rolling carriages:

Two connecting rods are always required for connecting two rolling carriages. These two connecting rods must be set to the same length. They are inserted in the mounts provided in the rolling carriages with the coupling rod on one side and the adjusting bolt on the other side.

NOTE:

If the traversing cylinder is to operate between the two rolling carriages, then the connecting rods must be mounted only after setting up the traversing cylinder.

6.1.9 Examples of traversing systems

CAUTION / ATTENTION!

If there is any doubt about the set-up of your traversing system you must contact a relevantly trained safety expert or LUKAS direct.

NOTE:

When setting up the traversing cylinder in combination with two rolling carriages there are two set-up possibilities:

1. The traversing cylinder is set up between the connecting rods of the rolling carriages.

2. The traversing cylinder is set up outside the connected rolling carriages.

The following gives a few examples of setting up of the traversing system:

1. Traversing system with a rolling carriage and separate load lifting (recommended variant)

Components required:

- 1 Hydraulic power pack

- 1 Control table

- Separate load lifting system (e.g. Hydraulic cylinder with required accessories)

- Rerailing bridge

- 1 Rolling carriage

- 1 Traversing cylinder

- Packing material (e.g. hardwood beams)

- Hose lines

2. Traversing system with two rolling carriages and separate load lifting (recommended variant)

Components required:

- 1 Hydraulic power pack

- 1 Control table

- Separate load lifting system (e.g. hydraulic cylinder with necessary accessories)

- Rerailing bridge

- 2 Rolling carriage

- 1 Traversing cylinder

- 2 Connecting rods

- Packing material (e.g. hardwood beams)

- Hose lines Example illustration single point lifting

Example illustration two point lifting

3. Traversing system with a rolling carriage and hydraulic cylinder standing on it

Components required:

- 1 Hydraulic power pack

- 1 Control table

- 1 Rolling carriage

- 1 Traversing cylinder

- 1 Hydraulic cylinder

- Packing material (e.g. hardwood beams)

- Hose lines

4. Traversing system with two rolling carriages and hydraulic cylinders standing on them

Components required:

- 1 Hydraulic power pack

- 1 Control table

- 2 Rolling carriage

- 1 Traversing cylinder

- 2 Hydraulic cylinder

- Packing material (e.g. hardwood beams)

- Hose lines

6.2 Start-up

ATTENTION!

During commissioning you must observe all the instructions and regulations from the separate operating instructions for all the components that you use in the rerailing system that is to be commissioned!

Work required before commissioning:

Before commissioning you must carry out a visual check for damage and leaks on all components being used. Damaged components must not be used and must be replaced! The hydraulic components must be bled to remove air before commissioning!

Bleeding the traversing cylinder:

Before commissioning and following repairs, the equipment must be deaerated.

- Connect the equipment to the hydraulic pump (see chapter “Connecting the equipment”).

- Fully extend and retract the device several times without load.

NOTE:

We recommend that during the bleeding, the attached unit for the hydraulic supply should stand at a higher level than the cylinder. The connections on the hydraulic cylinder should face upwards.

Commissioning:

CAUTION / ATTENTION!

Secure the vehicle to be rerailed in accordance with the regulations to prevent its rolling away, slipping and tipping over!

Set up all the components to be used as described in the Chapter "Setting up the LUKAS traversing system". When setting up you must comply with all the applicable standards, guidelines, regulations and statutes! The separate hydraulic supply and the control of the LUKAS traversing system must be outside the danger area! Then connect all the hydraulic components as described in the Chapter "Connecting the hydraulic equipment".

CAUTION / ATTENTION!

Make sure that there are no persons remaining in the danger area!

Observe the individual rerailing concepts of the vehicle manufacturer.

Only then should you commission the rerailing system!

6.3 Controlling the LUKAS traversing system with anchor pin

CAUTION / ATTENTION!

The vehicle ton be rerailed must be secured against rolling away, slipping and tipping over in accordance with the regulations!

NOTE:

You should note that the traversing distance of the cylinder is limited by its piston stroke! Depending on the location of the rolling carriages it may be that, under certain circumstances, the full traversing distance is only achieved during the second traversing procedure.

6.3.1 Traversing with external load lifting:

Procedure:

1. Set up the rerailing system as described in the Chapter "Setting up the LUKAS traversing system" and the separate operating instructions of the additional LUKAS components being used.

2. Lift the vehicle with the separate LUKAS load lifting system.

3. Place suitable support material (e.g. hardwood beams or metal plates) on the rolling carriages and align the rolling carriages in such a way that the vehicle has a stable and safe location after being put down.

CAUTION / ATTENTION!

The vehicle to be rerailed must be safely lifted up before packing up and aligning to prevent it from slipping away or tipping over. When packing up and aligning always also take account of the lifted vehicle! If the vehicle should start to move in an uncontrolled manner you should leave the danger area as quickly as possible! After packing up and aligning you must leave the danger area!

4. Place the vehicle on the rolling carriage.

5. Move the traversing cylinder using the control table until the end point of the traversing procedure is reached. If necessary, move the traversing cylinder.

It is strictly prohibited to work under loads suspended

exclusively by hydraulic means!

6. Move your separate LUKAS load lifting system so that the vehicle to be rerailed can be lifted safely again. The vehicle must remain secured against rolling away, slipping and tipping over!

7. Lift the vehicle to be rerailed and remove the support material from the rolling carriages.

8. Retract the traversing cylinder again.

9. Put the vehicle down with the separate LUKAS load lifting system.

NOTE:

If the traversing movement of the rerailing bridge is not adequate, the entire traversing system is relocated. When assembling the traversing system for the ﬁ rst time, make sure that allthe required preconditions in the Chapter "Setting up the LUKAS traversing system" are fulﬁ lled! You can then repeat the procedures 1 to 9.

10. Then remove the components of the traversing system being used again.

6.3.2 Traversing with the rolling carriages carrying the hydraulic cylinder(s):

Procedure:

1. Set up the rerailing system as described in the Chapter "Setting up the LUKAS traversing system" and the separate operating instructions of the additional LUKAS components being used.

2. Lift the vehicle with the hydraulic cylinder (the hydraulic cylinders) so that this cannot tip over or slip away.

CAUTION / ATTENTION!

The use of a step set in combination with the hydraulic cylinder standing on the rolling carriage is strictly prohibited!

3. Move the traversing cylinder using the control table until the end point of the traversing procedure is reached.

NOTE:

Y ou should note that the traversing distance of the cylinder is limited by its piston stroke! Depending on the location of the rolling carriages it may be that, under certain circumstances, the full traversing distance is only achieved during the second traversing procedure.

It is strictly prohibited to work under loads suspended

exclusively by hydraulic means!

4. Put the vehicle down by retracting the hydraulic cylinder on the rolling carriage. The vehicle must remain secured against rolling away, slipping and tipping over!

5. Remove the hydraulic cylinder(s) from the rolling carriage(s).

6. Retract the traversing cylinder(s) again.

NOTE:

7. Then remove the components of the traversing system being used again.

6.4 Controlling the DUO traversing cylinder with anchor cylinder

CAUTION / ATTENTION!

The vehicle ton be rerailed must be secured against rolling away , slipping and tipping over in accordance with the regulations! Observe the individual rerailing concepts of the vehicle manufacturer.

6.4.1 Traversing with external load lifting:

Procedure:

1. Set up the rerailing system as described in the Chapter "Setting up the LUKAS traversing system" and the separate operating instructions of the additional LUKAS components being used.

2. Lift the vehicle with the separate load lifting system.

CAUTION / ATTENTION!

4. Place the vehicle on the rolling carriage(s).

5. Secure the load against slipping away to the side.

6. Move the traversing cylinder until the end point of the traversing procedure is reached. If the traversing distance of 280 mm between a pair of slotted holes is inadequate you need to relocate the traversing cylinder. If the traversing distance is inadequate then continue with Item 11.

7. In order to relocate you must move the traversing cylinder to the middle of the slotted hole in order to guarantee ease of movement of the retracting/extending anchor cylinder. Now retract the anchor cylinder.

8. Now move the traversing cylinder to the middle of two holes.

9. Then extend the anchor cylinder again and move the traversing cylinder until the anchor cylinder engages again.

Without engaging in the slotted hole the rolling carriage may need to be secured against

rolling away if it is not aligned horizontally, in order to prevent inadvertent movement of the vehicle to be rerailed!

After engaging, the rolling carriages move in the direction of the traversing movement of

the traversing cylinder.

10. Items 7 to 9 can be repeated "as often as you need".

NOTE:

The traversing movement is only limited by the length of the rerailing bridge.

CAUTION / ATTENTION!

When traversing several times make sure that the rolling carriages are not pushed by the rerailing bridge!

1 1. Move your separate load lifting system for putting down so that the vehicle to be rerailed

can be lifted safely again. If it is not aligned horizontally, you must secure the rerailing bridge against rolling away, slipping and tipping over, in order to prevent inadvertent movement of the vehicle to be rerailed!

12. Lift the vehicle to be rerailed and remove the support material from the rolling carriages.

13. Put the vehicle down on the track with your separate load lifting system.

14. Move the traversing cylinder back into the start position.

15. Then remove the components of the traversing system being used again.

6.4.2 Traversing with the rolling carriages carrying the hydraulic cylinder(s):

Procedure:

1. Set up the rerailing system as described in the Chapter "Setting up the DUO traversing system" and the separate operating instructions of the additional components being used.

2. Lift the vehicle with the hydraulic cylinder (the hydraulic cylinders) so that this cannot tip over or slip away.

CAUTION / ATTENTION!

The use of a step set in combination with the hydraulic cylinder standing on the rolling carriage is strictly prohibited!

3. Move the traversing cylinder until the end point of the traversing procedure is reached. If the traversing distance of 280 mm between a pair of slotted holes is inadequate you need to relocate the traversing cylinder.

4. In order to relocate you must move the traversing cylinder to the middle of the slotted hole in order to guarantee ease of movement of the retracting/extending anchor cylinder. Now the anchor cylinder retracts.

6. Then extend the anchor cylinder again, causing it to lock the traversing unit again. You should move the anchor cylinder to the middle of the slotted hole before locking/ unlocking, in order to guarantee ease of movement of the piston as it moves in and out. Now move the traversing cylinder to the middle of two holes.

7. Without engaging in the slotted hole, the rolling carriage may need to be secured against rolling away if the rerailing bridge is not aligned horizontally, in order prevent inadvertent movement of the vehicle to be rerailed. Then extend the anchor cylinder again and move the traversing cylinder until the anchor cylinder engages again. After engaging, the rolling carriages move in the desired direction.

NOTE:

The traversing movement is only limited by the length of the rerailing bridge or the overall length of the combined rerailing bridges.

CAUTION / ATTENTION!

When traversing several times make sure that the rolling carriages are not pushed by the rerailing bridge!

8. Items 6 and 7 can be repeated "as often as you need".

9. Put the vehicle down on the track by retracting the hydraulic cylinder standing on the rolling carriage. The vehicle must remain secured against rolling away, slipping and tipping over!

10. Remove the hydraulic cylinder(s) from the rolling carriage(s).

11. Retract the traversing cylinder again.

12. Finally remove the components of the traversing system being used.

7. Dismantling the equipment / deactivation following operation

WARNING / CAUTION / ATTENTION! Before dismantling the rerailing equipment, please ensure that the moved load is in a stable and ﬁ rm position!

7.1 Hydraulic cylinder

After completion of the work, the hydraulic cylinders must be retracted leaving only a few mm*) projecting. This relieves the hydraulic and mechanical stress on the equipment.

NOTE:

When hydraulic cylinders and traversing cylinders are in storage, ﬂ uctuations in ambient temperature can cause the pistons to move slightly. This phenomenon is due to the difference in the expansion of the hydraulic ﬂ uid enclosed on the piston side and the rod side.

7.2 Hoses

First of all, decouple the pressure hose then the return hose as described in chapter “Connecting the equipment”. Ensure that you replace the dust protection caps onto the plug couplings.

ATTENTION!

The operating pressure in the system must be dissipated before uncoupling the hoses.

*) 1 mm = 0.04 in.

7.3 Additional components of the traversing system

Removal of all components is carried out in the reverse order to the installation and is described in the individual operating instructions of the components.

7.4 Hydraulic supply, control and separate load lifting systems

After completing the work, the hydraulic supply, control and any load lifting systems being used must be stopped. See the separate instruction manuals for these components!

8. Maintenance and service

A visual inspection must be carried out after every use, but at least once a year . Every 3 years, or if there is any doubt regarding the safety or reliability of the equipment, a functional test must also be performed. (Please also observe the relevant valid national and international regulations pertaining to service intervals of hydraulic equipment).

ATTENTION!

Clean off any dirt before checking the equipment!

WARNING / CAUTION / ATTENTION!

To perform maintenance and repairs, personal protection equipment appropriate for the work is an absolute requirement.

Inspections to be carried out:

Visual Inspection

• Cylinder and piston rod undamaged and not deformed,

• Cylinder accessories (e.g. piston protection plate) present and undamaged

• Rerailing bridge free from damage and deformation

• Connecting rods free from damage and deformation

• Rolling carriages free from damage and deformation

• General tightness (leaks),

• Handles present and securely bolted in place,

• All screwed connections tight

• Type plate, warning signs and other markings present and legible,

• Couplings must be easy to couple,

• Dust protection caps must be available,

• All accessories used not damaged

Functional test

• Piston stroke can be moved over full range inwards and outwards,

• Flawless and smooth extension and retraction of cylinders when pressurised.

• Rolling carriage moves perfectly without load.

• Connecting rods can be moved over full range inwards and outwards

• No unusual noises

9. Repairs

9.1 General information

Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and authorised LUKAS dealers. Only genuine LUKAS spare parts in the spare parts list must be used on all components. It is also imperative to take account of any special tools required, assembly instructions, safety aspects (also observe the Chapter "Care and Maintenance"). During the assembly work,

pay particular attention to the cleanliness of all components because dirt can damage the equipment!

WARNING / CAUTION / ATTENTION!

Protective clothes must be worn when repairs are being carried out, since the devices may also be pressurised when not in operation.

NOTE:

You should always contact LUKAS or an authorised dealer before using couplings from another manufacturer.

ATTENTION!

Because LUKAS devices are designed for the highest performance, only components may be replaced that are listed in the spare parts lists of the corresponding device. Other components in the device may only be replaced if:

- You have participated in an appropriate LUKAS service training course.

- You have the express permission of LUKAS Customer Service (after request, veriﬁ cation that permission may be granted. An examination in each individual case is necessary!)

9.2 Preventative service

9.2.1 Care instructions

The exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces.

9.2.2 Function and load test

If there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed.

9.2.3 Changing the hydraulic ﬂ uid in the traversing and anchor cylinders

- After approx. 200 deployments, but after three years at the latest, replace the hydraulic ﬂ uid.

ATTENTION!

Always perform the change of the hydraulic ﬂ uid over a collection tank and dispose of the collected ﬂ uid in a proper manner!

ATTENTION!

The hydraulic ﬂ uid must be completely replaced if the application conditions (ambient temperatures) change substantially. When selecting a suitable hydraulic ﬂ uid, please refer to chapter “Hydraulic ﬂ uid recommendations”.

Procedure:

1. Completely retract the cylinder.

2. Unscrew the hoses from the cylinder,

3. Drain off the hydraulic ﬂ uid,

4. Flush,

5. Reﬁ t the hoses correctly,

6. Connect the pump (hydraulic power pack) with new hydraulic ﬂ uid and move the cylinder in and out several times,

7. Bleed the cylinder as described in the Chapter "Commissioning",

8. Disconnect the pump (hydraulic power pack) again.

9.3 Repairs

9.3.1 Coupling replacement

The couplings must be replaced if:

- there is external damage,

- the locking does not function,

- hydraulic ﬂ uid continues to leak in the coupled/uncoupled state.

WARNING / CAUTION / ATTENTION!

Never repair couplings: they must be replaced by genuine LUKAS parts!

During assembly tighten the coupling to a torque of M

= 40 Nm.

Procedure:

1. Remove the coupling.

2. Place a new coupling in position and tighten to a torque of M

= 40 Nm.

9.3.2 Replacing the handles on the rerailing bridge

Any damaged or broken handles must be replaced.

Procedure:

1. Pull the damaged handle out almost to the stop.

2. Release the locking pins by pulling the metal rings back until the pins can be removed.

3. You can now remove the handle from the rerailing bridge and replace it.

4. Assembly is in the reverse order.

Securing pin

HandleHandle

9.3.3 Replacing the handles

on rolling carriages

All damaged or broken handles must be replaced.

Procedure:

1. Release the screws on the handle and remove them.

2. You can now remove the handle from the rolling carriage and replace it.

3. Assembly is in the reverse order.

Handle

Bolts

9.3.4 Replacing the handles on traversing cylinder

Any damaged or broken handles must be replaced.

Procedure for ﬁ xing directly on the traversing cylinder:

1. Release the screws on the handle and remove them, together with the washers underneath.

2. You can now remove the handle and replace it.

3. Assembly is in the reverse order.

Bolt

Washer

Handle

Procedure for ﬁ xing with clamps:

1. Release the screws and nuts and remove them.

2. Y ou can now remove the handle and the associated washers from the traversing cylinder and replace them. If there is damage to the clamps remove them towards the cylinder head. Make sure not to damage the hoses

3. Assembly is in the reverse order.

Handle

Washers

Bolts

Clamps

Nuts

9.3.5 Slider plate replacement on the traversing cylinder with anchor cylinder

A damaged, bent or broken slider plate must be replaced.

Procedure:

1. Release the screws on the anchor cylinder and remove them.

2. You can now remove the slider plate and replace it.

3. Assembly is in the reverse order. Make sure that the pin mounted in the anchor cylinder can move in the narrow slotted hole of the slider plate.

Narrow slotted hole

Bolts Slider plate

9.3.6 Replacing the hoses on traversing cylinder

Any damaged or leaking hoses must be replaced.

Procedure:

1. Unscrew the defective hoses at the cylinder and remove them, together with the seal rings underneath.

NOTE:

If just the hoses are defective, not the couplings, you must ﬁ rst unscrew the couplings before removing the hoses. After replacing the hoses these are mounted on the new hoses (see Chapter "Changing the couplings").

2. Place the seal rings on the hose connections of the cylinder and screw the new hoses in place. (Observe the tightening torque of M

= 35 Nm)

9.3.7 Decals

All damaged and/or illegible decals (safety notices, type plate etc.) must be replaced.

Procedure:

1. Remove damaged and/or illegible decals.

2. Clean surfaces with acetone or industrial alcohol.

3. Afﬁ x new decals.

When afﬁ xing take care to position the decals in the correct location. If this is no longer known, you should ask your authorised dealer or contact LUKAS directly.

Fault Check Cause Solution

Cylinder piston moves slowly or jerkily when activated

10. Troubleshooting

Are the hoses connected properly?

Does the pump unit work?

Pressure in control table OK? Read the pressure gauge

Air in the hydraulic system

Bleed the pump system (see operating instructions for hydraulic power packs)

Bleeding/depressurising the control table (actuating the pressure relief valves etc., see Control Table operating instructions)

Device doesn’t perform at its given power

Hoses cannot be coupled

Hydraulic ﬂ uid leak on the hoses or the ﬁ ttings

Visual check of hydraulic oil

Hydraulic ﬂ uid level in the supplying pump adequate?

Check operating pressure of driving hydraulic unit

Check device Device defective Remove the device from

Are the hoses defective?

Hydraulic oil too viscous because of ambient temperature.

Insufﬁ cient hydraulic ﬂ uid in the pump

Pressure supply has too low pressure

Pressurized Set hydraulic pump to

Coupling defective

Leak, possible damage

Replace the hydraulic oil by oil with the relevant viscosity

Top up hydraulic ﬂ uid, deaerate

If possible, increase max. operating pressure on the hydraulic unit to max. operating pressure of the cylinder or use another hydraulic unit with sufﬁ cient max. operating pressure.

service and repair it (have it repaired)

pressureless circulation

Coupling must be replaced immediately

Replace hoses

Fault Check Cause Solution

Damage on the surface of the hydraulic hose lines

Hydraulic ﬂ uid leaks on the piston rod

Mechanical damage or contact with aggressive agents

Defective rod seal Repair by an authorised

Damage to the piston

Replace hoses

dealer, by personnel specially trained by LUKAS, or by LUKAS itself

Leak from the couplings

Contact an authorised LUKAS dealer or the LUKAS Customer Service Department directly if the malfunctions cannot be rectiﬁ ed. The address for the LUKAS Customer Service department is:

LUKAS

Weinstrasse 39, D-91058 Erlangen, Germany PO Box 2560 D-91013 Erlangen

Tel.: (+49) 09131 / 698 - 348 Fax.: (+49) 09131 / 698 - 353

Hydraulik GmbH

Is the coupling damaged?

Coupling defective

Coupling must be replaced immediately

11. Technical data

Because all values are subject to tolerances, there may be small differences between the data for your device and the data in the following tables!

11.1 Traversing cylinder

Device type TC170 90-350F Value Units Remarks Item number 70-30-20

Dimensions l x w x h 653 x 156 x 177 mm retracted

25.7 x 6.2 x 6.9 in.

Length, extended 973 mm

38.3 in.

Force / Pushing 176 kN

39600 lbf.

Force / Pulling 92 kN

20700 lbf.

Stroke Total 320 mm

12.6 in.

Operating pressure max. 53 MPa

7700 psi

Volume of hydraulic ﬂ uid

509 cm³

31.1 cu.in.

Ambient

-20 … +55 °C

temperature

-4 … +131 °F

Weight 24 kg including hydraulic

ﬂ uid

52.9 lbs.

Speciﬁ cation of hydraulic ﬂ uid

Locking / Unlocking

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit

(differential volume on piston / rod side)

HM 10 ISO

6743-4

manual

Device type TC170 90-350 Value Units Remarks Item number 70-30-10

Dimensions l x w x h 668 x 363 x 197 mm retracted

26.3 x 14.3 x 7.7 in.

Length, extended 988 mm

38.9 in.

Force / Pushing 176 kN

39600 lbf.

Force / Pulling 92 kN

20700 lbf.

Stroke

Total 320 mm

12.6 in.

Operating pressure

max. 53 MPa

7700 psi

Volume of hydraulic ﬂ uid

509 cm³

31.1 cu.in.

Ambient temperature -20 … +55 °C

-4 … +131 °F

Weight

25 kg

including hydraulic

ﬂ uid

55.1 lbs.

Speciﬁ cation of hydraulic ﬂ uid

HM 10 ISO 6743-

Locking / Unlocking

Hydraulic

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit

(differential volume on piston / rod side)

Device type TC170 200-350 Value Units Remarks Item number 70-30-30

Dimensions l x w x h 685 x 370 x 214 mm retracted

27.0 x 14.6 x 8.4 in.

Length, extended 1007 mm

39.7 in.

Force / Pushing 337 kN

75800 lbf.

Force / Pulling 207 kN

46500 lbf.

Stroke Total 322 mm

12.7 in.

Operating pressure max. 53 MPa

7700 psi

Volume of hydraulic ﬂ uid 793 cm³

48.4 cu.in.

Ambient temperature -20 … +55 °C

-4 … +131 °F

Weight

44 kg

including hydraulic

ﬂ uid

97 lbs.

Speciﬁ cation of hydraulic ﬂ uid

Locking / Unlocking

Hydraulic

HM 10 ISO

6743-4

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit

(differential volume on piston / rod side)

11.2 Rolling carriage

Device type RC-700/350 RC-1000/350 Item number 840720640 840721631

Dimensions

(L x B x H)

max. width of rerailing bridge

max. permitted load

Weight

[mm] 390 x 380 x 130 360 x 380 x 154

[in.] 15.4 x 15 x 5.12 14.2 x 15 x 5.5

[mm] 350 350

[in.] 13.8 13.8

[kN] 750 1000

[lbf.] 168600 224800

[kg] 41.5 62

[lbs.] 91.7 139

11.3 Rerailing bridges

Device type 1.1 m / 85 mm 2.2 m / 85 mm 3.3 m / 85 mm Item number 840726391 840725792 840725093

Dimensions

(L x B x H)

Weight

[mm] 1100 x 350 x 85 2200 x 350 x 85 3300 x 350 x 85

[in.] 43.3 x 13.8 x 3.35 86.6 x 13.8 x 3.35 130 x 13.8 x 3.35

[kg] 34 68 102

[lbs.] 75 15 225

Device type 1.1 m / 140 mm 2.2 m / 140 mm Item number 840726350 840725750

Dimensions

(L x B x H)

Weight

Device type 3.3 m / 140 mm 4.4 m / 140 mm Item number 840725050 840726550

Dimensions

(L x B x H)

Weight

[mm] 1100 x 350 x 140 2200 x 350 x 140

[in.] 43.3 x 13.8 x 5.5 86.6 x 13.8 x 5.5

[kg] 40 80

[lbs.] 88 176

[mm] 3300 x 350 x 140 4400 x 350 x 140

[in.] 130 x 13.8 x 5.51 173 x 13.8 x 55.1

[kg] 120 160

[lbs.] 265 353

Device type 1.1 m / 184 mm 2.2 m / 184 mm Item number 840726381 840726382

Dimensions

(L x B x H)

Weight

Device type 3.3 m / 184 mm 4.4 m / 184 mm Item number 840726383 840726384

Dimensions

(L x B x H)

Weight

[mm] 1100 x 350 x 184 2200 x 350 x 184

[in.] 43.3 x 13.8 x 7.24 86.6 x 13.8 x 7.2

[kg] 70 140.5

[lbs.] 154 310

[mm] 3300 x 350 x 184 4400 x 350 x 184

[in.] 130 x 13.8 x 7.24 17.3 x 13.8 x 7.24

[kg] 211 281

[lbs.] 465 620

11.4 Connecting rods

Device type 1830/1030 2800/1500 Item number 840720571 840720575

Length(retracted)

Length(extended)

Dimensions

(diameter)

Weight

[mm] 1030 1500

[in.] 40.6 59.1

[mm] 1830 2800

[in.] 72.1 110

[mm] 65 50

[in.] 2.6 2

[kg] 40 58.5

[lbs.] 88 129

11.5 Recommended hydraulic ﬂ uids

Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment

Oil temperature range Oil designation Viscosity rating Remarks

A -24 .... +30°C HL 5 VG 5

B -18 .... +50°C HM 10 VG 10

C -8 .... +75°C HM 22 VG 22

D +5 .... +80°C HM 32 VG 32

E -8 .... +70°C HF-E15 VG 15 Bio-oil

Oil temperature range Oil designation Viscosity rating Remarks

A B C

D +41.0 .... +176°F HM 32 VG 32

-11.2 .... +86°F HL 5 VG 5

-0.4 .... +122°F HM 10 VG 10

+17.6 .... +167°F HM 22 VG 22

+17.6 .... +158°F HF-E15 VG 15 Bio-oil

recommended range of viscosity: 10...200 mm²/s Supplied with HM 10 DIN ISO 6743-4.

(10…200 cSt.)

11.6 Operating and storage temperature ranges

Operating temperature [°C] -20 … +55 Ambient temperature (device in operation) [°C] -25 … +45 Storage temperature (device not in operation) [°C] -30 … +60

Operating temperature [°F] -4 … +131 Ambient temperature (device in operation) [°F] -13 … +113 Storage temperature (device not in operation) [°F] -22 … +140